Yamaha Tmax XP500Z Specifications

XP500 TMax Technical Orientation Guide
FEATURES AND BENEFITS
Offering high levels of performance, comfort and sophistication, the new TMax superscooter looks
sure to make as great an impression on the powered two wheeler market as the first Yamaha YZFR1 made in the motorcycle scene.
ENGINE FEATURES
CHASSIS FEATURES
n 499cc liquid cooled 4-stroke parallel twin
engine
n DOHC 8 valve engine
n High capacity V-belt transmission
n Horizontally opposed reciprocating balancer
n Wet multiple plate automatic centrifugal
clutch
n New design air intake route and air filter case
n Low position radiator
n Semi dry sump with oil cooler
n Non adjustable 2-stage silent chain drive train
n Motorcycle-type high rigidity diamond shape
frame
n Motorcycle-type front fork
n Highly rigid swingarm
n 14 inch front and rear wheels
n Motorcycle-type hub with fixed rear wheel axle
n Sport bike type weight distribution
n 50º lean angle
n 33 liters luggage compartment
n 1 piece dual seat with 3-stage adjustable
backrest
ELECTRICAL FEATURES
n Dual multi-reflector headlight
n Stylish combination taillight
n Automobile-type meter panel with extensive
information
n High capacity power supply
n Anti-theft alarm pre-wiring
n Grip warmer pre-wiring
n Mobile phone charger pre-wiring
1
XP500 TMax Technical Orientation Guide
ENGINE SYSTEM
Displacing 499 cc, the TMax’s highly-advanced fully automatic twin-cylinder DOHC liquid-cooled
4-stroke 8-valve engine is one of the most powerful designs available on scooters today.
A key feature of its configuration is that unlike most traditional scooter engines which pivot as one
unit with the rear suspension, this engine is fixed rigidly into the TMax’s strong tubular diamond-shape frame
in order to achieve higher levels of chassis rigidity for enhanced handling performance. The swingarm is
mounted to a pivot point at the rear of the engine, thereby keeping unsprung weight low for more responsive
rear suspension action.
Another innovative feature is the horizontal configuration of the engine that keeps the centre of gravity
low for easy handling and also gives extra storage space under the dual seat.
ENGINE FEATURES
n Parallel twin with 360 degree crankshaft
n 66 mm bore and 73 mm stroke
n 10.1 :1 compression ratio
n Left side drive cam chain for reduced engine width
 Horizontal compact cylinder head
‚ Horizontally opposed reciprocating balancer
ƒ Semi dry sump
„ High capacity V-belt transmission
… Wet multiple plate automatic centrifugal clutch
† Non adjustable 2-stage silent chain drive train
‡ Pivot coaxial drive shaft eliminates chain backlash
4
2
3
1
5
2
7
6
XP500 TMax Technical Orientation Guide
CYLINDER HEAD
n
n
n
n
4 valves per cylinder, DOHC
Torsion type auto cam chain tensioner (similar to YZF-R1)
“Shim-under-bucket” valve adjustment for long maintenance interval (same as YZF-R1/YZF-R6)
Valve clearance at cold engine condition:
Intake : 0.15 - 0.20 mm
Exhaust: 0.25 - 0.30 mm
1
2
 Intake camshaft
‚ Cam chain tensioner
ƒ Exhaust camshaft
„ Silent cam chain
4
3
Intake
port
Exhaust
port
Air Induction
Ports
TDC
105º
(1)
25.0
22.0
(2)
4.0
4.0
(3)
83.3
82.8
25º
105º
OL 50º
Intake valve Exhaust valve
(mm)
(mm)
(2)
(3)
25º
IN
EX
55º
55º
BDC
(1)
VALVE TIMING
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XP500 TMax Technical Orientation Guide
CYLINDER
n New liquid-cooled cylinder body for low weight
n Left side cam chain drive for reduced engine width
n Ceramic composite cylinder coating for increased cooling and longer wear life
Side view
Side cam chain drive
ø 66.0 mm
ø 66.0 mm
Top view
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XP500 TMax Technical Orientation Guide
CRANKSHAFT / BALANCER
n New design crankshaft uses replaceable full circumference plain bearings
n Horizontally opposed reciprocating balancer for excellent vibration reduction
This type achieves same vibration reduction as 3 balancer shafts to reduce primary and secondary inertial forces, while requiring less space.
 Piston cylinder #1
‚ Piston cylinder #2
ƒ Cam chain drive gear
„ Balancer piston
1
2
bearing size indication
3
4
Bearing size indication, reading from left to right (ex. 1 2 3 4 5):
 Left main bearing
‚ Right main bearing
ƒ Conrod bearing cylinder #1
„ Conrod bearing balancer cylinder
… Conrod bearing cylinder #2
Balancer cylinder
5
XP500 TMax Technical Orientation Guide
PISTON
n New combustion piston with V-groove between upper and lower compression rings for improved
sealing
n Balancer piston for horizontally opposed reciprocating balancing system
COMBUSTION PISTON
Top view
V-groove
Cross-section
Side view
ø 40 mm
ø 66
BALANCER PISTON
Top view
Front view
Side view
71.7
mm
ø 58
Front view cross-section
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XP500 TMax Technical Orientation Guide
CONNECTING ROD
n Newly designed connecting rods: 2 for combustion, 1 for balancer
n New type connecting rod as integral part of the horizontally opposed reciprocating balancing
system
FOR BALANCER
FOR COMBUSTION
16
mm
117 mm
124.5 mm
15
mm
45 mm
45 mm
All connecting rods use the same 2-piece plain bearings
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XP500 TMax Technical Orientation Guide
TRANSMISSION SYSTEM
CONTINUOUSLY VARIABLE TRANSMISSION
n Highly efficient V-belt transmission in order to obtain high performance
n Newly designed cooling system with fins on both rotors of the secondary sheave for improved
cooling and higher belt durability
n Cooling system uses 2 air filters to provide high volume clean air cooling
2
1
3
4
Engine left side
Engine right side
5
 Left transmission air filter
‚ Air intake duct to transmission
ƒ Right transmission air filter
„ Air exhaust ports
… Cooling fin
† Secondary sheave
6
V-belt exchange: each 20,000 km
Engine cross-section
rpm
Speed shift rate diagram
speed
8
XP500 TMax Technical Orientation Guide
CLUTCH
n Wet type multiple plate centrifugal clutch for smooth power transmission and to meet XP’s
higher torque
n Clutch uses diaphragm type spring
 Friction plates: 5 pieces
‚ Clutch plates: 6 pieces
ƒ Diaphragm clutch spring
„ Primary drive gear
… Main axle
1
3
4
† First pinion gear
‡ Secondary shaft
ˆ First wheel gear
‰ Drive axle
Š Primary driven gear
5
6
7
8
5
10
9
2
Transmission gear reduction ratio
= (primary driven gear / primary drive gear) x (first wheel gear / first pinion gear)
= (52 / 32) x (36 / 22)
= 2.659
Clutch-in revolution: 1800 ± 300 rpm
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XP500 TMax Technical Orientation Guide
FINAL DRIVE
n Newly designed final drive with non-adjustable 2-stage silent chain for an efficient power transmission, reduced noise and low maintenance
n High speed first stage chain with spring-type torque absorber for a further reduction of noise
n The final drive and the swingarm are integrated for improved rigidity and high speed stability
 Crankcase
‚ Drive axle
ƒ First stage drive chain
„ Second stage drive chain
… Taper roller bearing
1
2
3
Mounted on rear wheel
clutch hub
5
Gear ratio: (41 / 25) x (40 / 29) = 2.262
 Rear drive case
‚ Oil dip stick
4
1
Final drive oil capacity: 700 cc
Type: SAE 80, hypoid
2
Oil level
10
XP500 TMax Technical Orientation Guide
LUBRICATION SYSTEM
n
n
n
n
n
Semi dry sump system for reduced engine size
Oil tank is incorporated into the left crankcase cover
Newly designed dual stage oil pump
Liquid-cooled oil cooler with cartridge type oil filter (5DM-13440-00)
New type oil drain bolt that allows oil from crankcase and oil tank to be drained at the same time
Dual stage oil pump brings oil from oil tank to respective areas of the engine, including a spray bar
over the starter gears and the stator assembly.
The oil pump also has a scavenging pump that returns the oil to the oil tank.
The scavenged oil fills the tank until it is full and then overflows back into the sump area to maintain a constant level in the sump.
 Oil filter
‚ Oil cooler
ƒ Oil spray bar
„ Crankcase cover
… Oil tank space
† Oil pump
‡ Drain bolt
3
4
5
1
2
7
6
Engine oil capacity
Total amount
: 3.6 liters = 2.2 liters in crankcase + 1.4 liter in oil tank
Without oil filter replacement : 2.8 liters
With oil filter replacement : 2.9 liters
Engine oil change: every 5,000 km
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XP500 TMax Technical Orientation Guide
LUBRICATION SYSTEM
LUBRICATION FLOW CHART
12
XP500 TMax Technical Orientation Guide
LUBRICATION SYSTEM
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XP500 TMax Technical Orientation Guide
COOLING SYSTEM
n Low mounted radiator for design flexibility
n Automatic air bleed for easy maintenance
 Coolant Reservoir Tank
‚ Thermostat
ƒ Radiator
„ Water pump
… Coolant Fan
† Radiator Cap
Cooling system capacity: 1.5 liter
Carburetor heating thermostat:
Coolant temperature is less than 80±2 ºC: OPEN
Coolant temperature is more than 80±2 ºC: CLOSED
Main thermostat:
Coolant temperature is less than 82±2 ºC: OPEN
Coolant temperature is more than 82±2 ºC: CLOSED
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XP500 TMax Technical Orientation Guide
CARBURETION SYSTEM
n
n
n
n
n
Twin BS30 round slide carburetors
Automatic choke for easy starting
Throttle Position Sensor to optimize ignition timing and reduce emissions
Coolant type carburetor heater
Pull-pull type throttle control
 Auto Choke Unit
‚ Throttle Position Sensor
2
1
Carburetor settings
Marking
5GJ1
Main jet
#105
Jet needle
4DK4-3
Needle jet
0 - 0M
Pilot jet
#22.5
Pilot screw turns out
2 1/2
Auto-choke electricity control.
By thermo switch.
coolant temperature is more than 60 ± 3ºC: ON
coolant temperature is less than 55 ± 3ºC: OFF
By TCI Unit
more than 800 rpm: ON
less than 375 rpm: OFF
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XP500 TMax Technical Orientation Guide
AIR INTAKE SYSTEM
n Air filter case position in upper front body cowling for effective use of space
n Air intake system uses noise reduction box
n Air Induction System for reduced emissions
 Air filter case
‚ Noise reduction box
ƒ Vacuum hose to Air Cut Valve
„ Fuel pump
… Reed valve
† Air hose (Reed Valve - Air Cut Valve)
‡ Air Cut Valve
1
See Service Tips for CO adjustment and
Air Induction System check procedure
2
7
3
4
6
To exhaust port
5
BLOCK HERE FOR CO ADJUSTMENT
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XP500 TMax Technical Orientation Guide
EXHAUST SYSTEM
n 2 into 1 stainless exhaust pipes and stainless muffler
 Muffler
‚ Exhaust Pipe
ƒ EGA connection
1
2
17
3
XP500 TMax Technical Orientation Guide
CHASSIS
Like the all-new engine, the TMax’s advanced high-rigidity chassis has been developed using some
of the latest motorcycle technology in its frame and suspension designs.
n Sports bike type front and rear weight distribution of 47% and 53% respectively
n Ground clearance: 140 mm
n 50º lean angle
FRAME
n Newly designed tubular diamond shape frame
n Frame uses engine as a stressed member for added rigidity and enhanced handling performance
n Total configuration keeps centre of gravity low and wheelbase short
References
XP500
YP250
Overall length 2,235 mm 2,120 mm
Wheelbase
Min. turn radius
Engine mounting positions
18
1,575 mm 1,540 mm
2.8 m
2.6 m
XP500 TMax Technical Orientation Guide
FUEL TANK
n
n
n
n
Steel fuel tank just under rider seat
Fuel lid in rider seat with easy access to fuel cap
Fuel tank capacity is 14 liters
Electric fuel pump for stabilized fuel supply uses external fuel filter
 Fuel lid
‚ Fuel tank cap
ƒ Fuel tank
1
2
3
BODYWORK
n Completely new aerodynamically-efficient sports styled bodywork
 Integrated turn signal lights
‚ Aluminium grab bar for improved passenger comfort
1
2
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XP500 TMax Technical Orientation Guide
WINDSCREEN
n Large size windscreen for enhanced weather protection
n Newly designed cowling mounted mirrors
SEAT
n One piece deeply padded dual seat
n Rider seat features adjustable backrest offering 35 mm of movement in three stages
n Seat is locked at left and right side for enhanced security
 Fuel lid
‚ Adjustable backrest
2
1
35 mm
Seat height: 795 mm
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XP500 TMax Technical Orientation Guide
STORAGE COMPARTMENTS
n Small compartment in the right side front cowling of 1.2 liter for sunglasses, mobile phone, etc.
n Rear storage compartment under seat of 33 liters and it can hold a full face helmet or B4 size bag
n Rear storage compartment has an interior light, a special area for a U-lock and pre-wired for a 12V
accessory plug
„ Battery
… Seat locks
† Fuse box
 Front storage compartment
‚ Rear storage compartment
ƒ Interior light
2
1
336 mm
3
6
5
340 mm
5
440 mm
21
4
XP500 TMax Technical Orientation Guide
FRONT SUSPENSION
n Motorcycle type front suspension uses upper clamp and 38 mm fork tubes for increased high
speed stability
n Front wheel travel: 120 mm
 Lower clamp
‚ Upper clamp
ƒ Ball bearings
2
Top view
1
3
Oil level: 135 mm
Oil type: SAE 7.5 WT
REAR SUSPENSION / SWINGARM
n Single pull type rear shock absorber horizontally positioned underneath the engine for low centre
of gravity and increased storage space
n Swingarm and final drive are combined for improved rigidity
n Swingarm pivots independently of engine for more responsive suspension reaction
n Rear wheel travel and shock absorber stroke: 120 mm
 Swingarm
‚ Shock absorber
Top view of swingarm
Final drive
1
2
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XP500 TMax Technical Orientation Guide
FRONT WHEEL / TIRE / BRAKE
n New 14 x MT 3.50 cast wheel
n Front disc brake diameter: 282 mm
n Front brake: two piston pin slide-type caliper
 Front brake caliper
Front wheel
Tires.
Dunlop
Bridgestone
: D305FA 120/70-14 M/C 55S
: HOOP B03 120/70-14 M/C 55S
REAR WHEEL / TIRE / BRAKE
n
n
n
n
New 14 x MT 4.50 cast wheel
Rear wheel uses motorcycle-type clutch hub and fixed axle for enhanced stability
Rear disc brake diameter: 267 mm
Rear brake: 1 piston pin slide-type caliper
 Rear brake caliper
‚ Clutch hub
1
2
Tires.
Dunlop
Bridgestone
: D305 150/70-14 M/C 66S
: HOOP B02 150/70-14 M/C 66S
23
1
XP500 TMax Technical Orientation Guide
ELECTRICAL SYSTEM
GENERATOR
n The generator supplies ample power for electrical accessories
n Generator capacity: 22A, 14V @ 5000 rpm
n The optional electrical accessories are: mobile phone charger, grip warmers and anti-theft alarm system
HEADLIGHT ASSEMBLY
n Newly designed multi-reflector dual headlight
 Low beam
‚ High beam
ƒ Auxiliary lights
: 12V, 55W (H7 - 12V, 55W)
: 12V, 60W (H4 - 12V, 60/55W)
: 12V, 5Wx2
For UK specifications, the positions of the left and right headlights are opposite
1
2
3
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XP500 TMax Technical Orientation Guide
TAILLIGHT ASSEMBLY
n Newly designed dual taillight
 Tail / brake light : 12V, 21/5W
‚ Turn signal light : 12V, 21W
ƒ License plate light : 12V, 5W
License plate light
Taillight
2
2
3
1
LEAN ANGLE CUT-OFF SWITCH
Shuts off fuel pump if TMax falls on its side with running engine
Switch can not be activated if TMax is leaned over while cornering
If activated, the main switch must be turned “off” and then back “on” again to start the engine
ANTI-THEFT ALARM PRE-WIRING
n Main wiring harness is pre-wired from factory with connectors for an aftermarket alarm system
n Location: behind left side body cover
GRIP WARMER PRE-WIRING
n Main wiring harness is pre-wired from factory with connectors for an aftermarket grip warmer
n Location: under handlebar cover
MOBILE PHONE CHARGER PRE-WIRING
n Main wiring harness is pre-wired from factory with connectors for an aftermarket mobile phone charger
n Location: behind right side body cover
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XP500 TMax Technical Orientation Guide
INSTRUMENTATION
n Automobile-style instrument panel for extensive information and easy reading
n Speedometer uses electronic front wheel speed sensor (same type as FZS600)
n Main switch has luminescent ring (similar to YP250)
 Digital clock
‚ Speedometer with integrated trip/odometer
ƒ Coolant temperature gauge
„ Fuel gauge
… Oil indicator reset button
1
10
9
8
† Trip meter reset button
‡ High beam indicator
ˆ V-belt change indicator
‰ Engine oil change indicator
Š Time set buttons (left minutes / right
hours)
2
7
3
6
4
5
l Oil change indicator lights up at 1,000 km, 5,000 km and then every 5,000 km.
l V-belt indicator lights up every 20,000 km.
See Service Tips for details.
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XP500 TMax Technical Orientation Guide
SERVICE TIPS
The Service Tips portion of the Technical Orientation Guide is designed to further familiarize you
with some key servicing points of the TMax. It is not designed to replace the TMax Service Manual.
For complete servicing details please refer to the Service Manual.
ENGINE OIL LEVEL CHECK
Start checking from cold engine condition.
n Put the TMax on the main stand on level ground and check that the oil is at minimum level in the
sight glass. If not, add enough oil to bring it up to the minimum level and start the engine for
about 2 to 3 minutes so the oil sufficiently circulates through the system.
n Turn the engine off and let it sit for a couple of minutes to allow the oil to settle into the sump
and recheck the level. Add oil to the tank if necessary until the oil is at the proper level in the
sight glass.
FINAL DRIVE OIL LEVEL CHECK
With the TMax still on the main stand:
n Remove the two screws and the plastic cover on the left side of the swingarm
n Remove the dipstick and wipe clean
n Reinsert the dipstick but do not screw it in
n Remove again and check the level. If it is below the full level add oil accordingly.
RADIATOR FILL
The radiator fill cap is located just inside the lower right side of the front fairing near the front tire.
COOLANT RESERVOIR
There is a small cutout on the right side cowl under the floorboard area to check the reservoir
coolant level. If coolant is below the minimum level, pull up the rubber floorboard mat and remove
the screw that holds the filler cap access lid and the cap to add coolant.
AIR FILTER REPLACEMENT
n Remove the mirrors and the windshield with the base, do not remove the windshield from the
base, to access the air box.
n Remove the airbox cover and air filter.
PROPER REMOVAL OF THE MIDDLE SIDE PANELS
Some caution should be taken when removing these panels to prevent damaging them.
n Remove the two allen screws from the front and the allen screw near the passenger footrest
n Now pull on the bottom of the panel to pop the tabs out of the rubber grommets
n Then push the panel upward from the bottom to pop out the top section.
FUEL PUMP AND FILTER
The fuel pump and filter are located underneath the right middle side panel.
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XP500 TMax Technical Orientation Guide
CARBURETOR ACCESS
Carburetor adjustment is easily accessible through the center of the floorboard. The vacuum plugs
for carburetor synchronization are on the intake manifolds and the fuel mixture screws for CO
adjustment are on the top of carburetors.
AIR CUT VALVE
The Air Cut Valve for the Air Induction System is located under the windshield on the left side of
the air box.
AIR INDUCTION SYSTEM REED VALVE
When performing the CO adjustment, be sure to block off the large hose to the reed valve located
under the left floorboard. This will prevent air from entering the system and giving inaccurate readings.
CO ADJUSTMENT / AIR INDUCTION SYSTEM CHECK PROCEDURE
CO ADJUSTMENT
1
2
3
4
5
Cut the secondary air supply by blocking the hose between the Air Cut Valve and the Reed Valve
(See pg.16 for Illustration).
Connect the exhaust gas analyzer to the head pipe fittings.
Disconnect the crankcase breather hose. This will prevent any oil contamination or combustion
blow-by from affecting the EGA readings.
Warm up the engine for several minutes at idle rpm.
Adjust the CO while maintaining the following conditions::
n Oil temperature
:
65 ~ 75 ºC
n Coolant temperature
:
75 ~ 85 ºC
n Intake vacuum
:
33 ~ 39 kPa
n Idle revolution
: 1150 ~ 1250 rpm.
CO measurement should be: 3.0%
AIR INDUCTION SYSTEM CHECK PROCEDURE
1
2
3
Adjust CO following the above procedure.
Restore the secondary air supply to the air induction system unit.
Check the CO reading while maintaining the above conditions (oil temperature, coolant tempera ture , intake vacuum and idle rpm).
4 CO reading should be: 0.5%
NOTE: Reconnect the crankcase breather hose and check the CO reading again. If the CO level is much
higher, the engine oil may be contaminated with gasoline or the engine may be suffering from poor
mechanical condition. Change the engine oil and check the CO level again. If the reading is still out of
specification, check the engine for a mechanical problem.
V-BELT TRANSMISSION AIR FILTERS
One of the V-belt transmission air filters is located under the left side panel next to the fuel tank and the
other one is inside the right crankcase cover in front of the secondary sheave.
HEADLIGHT BULB ACCESS
The head light bulbs can be accessed by reaching up under the front cowling.
TAILLIGHT AND REAR TURN SIGNAL BULB ACCESS
The taillight and turn signal bulbs can be accessed after removing the aluminium grab rail, middle and side
sections of the tail cowl.
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XP500 TMax Technical Orientation Guide
OTHER COMPONENTS LOCATED UNDER REAR COWL
n The Main fuse, starter relay, flasher relay, starter cut-off relay, fuel pump relay, seat lock cable junction
and regulator/rectifier are all located under the right side rear cowl.
n The stator, pick up coil and alarm connectors are located under the left side.
THERMO SENSOR AND THERMO SWITCH
The thermo switch for the auto choke is located directly on the thermostat housing and the thermo
sensor for the temperature gauge is next to the thermostat on the cylinder. The electric cooling fan is
mounted directly on the radiator and is controlled by a thermo switch mounted on the left upper
corner of the radiator.
REAR WHEEL REMOVAL
To remove the rear wheel, place the TMax on the main stand on level ground.
n Take off the plastic cover on the left side of the swingarm.
n Remove the axle nut.
n Remove the rear brake caliper from the swingarm.
n Loosen the axle pinch bolt on the right side.
n Remove the axle and spacer.
n Pull the wheel to the right to slide the hub out of the splines and pull the wheel out of the swingarm.
n Be sure to grease the hub splines before re-installation.
V-BELT REPLACEMENT
The V-belt on the TMax can be replaced by taking off:
l Right middle side panel
l Right floorboard
l Small shroud
l Rear passenger footpeg
l Muffler stay bolt
l Plastic cover from V-belt transmission cover.
n Move the fuel filter and pump out of the way.
n Remove the V-belt transmission cover while moving the muffler out of the way.
n Install two 45 x 6 mm bolts into the threaded holes of the secondary sheave.
n Tighten the bolts evenly until the secondary sheave is spread apart far enough so that the V-belt can be
removed.
n Install the new belt and remove the bolts.
To reset the V-belt indicator light, disconnect the 2-pin jumper connector for 2 to 5 seconds with the
main switch turned on, then reconnect it.
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XP500 TMax Technical Orientation Guide
CHECKING TDC AND CAM TIMING POSITION
n
n
n
n
Remove the left and right floorboards as shown earlier.
Remove the valve cover according to the service manual.
Remove the inspection plug on the left crankcase cover just above the water pump.
Remove the small cover on the front of the right side crankcase cover to access the primary
sheave nut.
n Rotate the primary sheave nut clockwise until the TDC mark on the rotor is aligned with the
mark in the inspection window. The number one cylinder will also be at TDC of its compression stroke
when the small holes on both camshaft sprockets are even with the cylinder head surface and facing
towards the intake side of the engine.
VALVE ADJUSTMENT PRECAUTION
Because of the near horizontal angle of the cylinder head, the exhaust valve lifters may have a tendency to
slide out of their pockets when the cams are removed. If this occurs the adjustment shim may fall out of the
valve retainer and damage the cylinder head if the engine is run in this condition.
To prevent this from happening, apply a small amount of grease to the adjusting shim and the valve
lifter before reassembly. This will hold the shim and lifter in place while the cams are reinstalled
and timed.
RESET ENGINE OIL CHANGE INDICATOR
To reset the engine oil indicator, push the oil indicator reset button on the instrument panel for 2 - 5
seconds. The required reset time is to prevent accidentally resetting the oil change indicator (i.e. the
counter in the igniter-unit). See also Self-diagnostics.
SELF-DIAGNOSTICS
The oil indicator light of the TMax has 3 functions:
n Oil indicator bulb check
n Indicate replacement timing of engine oil
n Indicate an electrical problem (self-diagnostics).
Function 1
The oil indicator lights up momentarily when the main switch is turned on, in order to indicate that the oil
indicator light bulb is working properly.
Function 2
The oil indicator lights up continuously in order to indicate that the engine oil has to be replaced.
It lights up initially at 1,000 km and 5,000 km, after that it lights up every 5,000 km (10,000 15,000 - etc.).
NOTE:
The mileage is counted by the igniter after every reset, it therefore is possible that the timing of the
light is different from the odometer reading.
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XP500 TMax Technical Orientation Guide
Function 3
If the igniter detects an electrical problem, the engine oil indicator will flash according to patterns mentioned
as Condition Codes in the table below.
Circuit
TPS l
l
l
Defect(s)
System Response
Disconnected l The igniter-unit stays set to wide-open
Short circuit.
throttle ignition timing.
Mechanical l Oil indicator displays condition code.
Malfunction.
Condition Code
Speed l Disconnected l Oil indicator displays condition code.
Sensor
Remarks
Light on : 0.5 s
Light off : 0.5 s
Pattern interval: 3.0 s
Lean l Disconnected l The system stops fuel pump operation.
Angle l Short circuit. l Oil indicator displays condition code.
Switch l Mechanical
Malfunction.
SPECIAL TOOLS
There are three new special tools introduced for the TMax:
Primary Clutch Holder
Part Name
Part Number
Primary Clutch Holder
90890-01482
Sheave Holder
90890-01481
Plain Bearing Installer/Remover 90890-04139
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XP500 TMax Technical Orientation Guide
PRIMARY SHEAVE REMOVAL AND DISASSEMBLY
After the V-belt has been removed:
n Install the sheave holder on the primary sheave.
n Take off the nut.
n Take off the front sheave.
n Take off the rear sheave from the
crankshaft.
To disassemble the primary sheave:
n Remove the screws.
n Remove the sheave cap.
n Remove the cam.
n Remove and inspect the weights and sliders
for damage.
Sheave holder used on primary sheave
Clean and check the sheave surfaces for cracks or other damage. Clean the entire sheave assembly of the
old grease and repack it with 80 to 90 grams of the same special sheave grease as used on the YP250 and
re-assemble.
When re-installing the primary sheave on the crankshaft, be sure to grease the crankshaft splines with the
special grease and that the sheave plate splines are properly aligned with the crankshaft splines.
SECONDARY SHEAVE REMOVAL AND DISASSEMBLY
Follow the same procedures for the secondary
sheave removal as the primary sheave using the
opposite side of the sheave holding tool:
n Install the secondary spring compressor tool in
a vise.
n Install the secondary sheave onto the tool.
n Remove the nut and spring from the assembly.
n Then separate the sheaves by removing the collar
and pins from the cam.
Sheave holder used on secondary sheave
Clean and inspect all parts for wear or damage. Lube all sliding parts with assembly lube and reassemble
the sheave.
MAIN BEARING REPLACEMENT
Because the TMax uses full circumference plain
bearings, it is necessary to use the special bearing
installer/remover to remove and install them.
Use extreme caution when installing these
bearings to prevent damage.
For detailed drawings and instructions refer to the
XP500 Service Manual.
32
Following special tools are NOT new, but they are used only for ATV.
It is possible that motorcycle dealers have do not have the proper tools.
XP500 TMax Technical Orientation Guide
PERIODIC CHECKS AND ADJUSTMENTS
This chapter includes information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service
technicians should be familiar with this entire chapter.
33
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
XP500 – General Specifications
Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Weight:
Dry (without oil and fuel)
Wet (with oil and a full fuel tank)
Maximum load-except motorcycle
Performance:
Minimum turning radius
Engine:
Engine type
Cylinder arrangement
Displacement
Bore x stroke
Compression ratio
Standard compression pressure (at sea level)
Starting system type
Lubrication System:
Type
Oil Type or Grade:
Engine oil
Chain drive oil
Oil Capacity:
Periodic oil change
With oil filter replacement
Total amount
Chain Drive Oil:
Total Amount
Radiator
Capacity (including all routes)
Air Filter:
Type
Fuel:
Recommended fuel
Fuel tank capacity
Carburetor:
Type/quantity
Manufacturer
Spark Plug:
Type
Manufacturer
Spark plug gap
2235mm
775mm
1410mm
795mm
1575mm
130mm
197kg
217kg
183kg
2800mm
Liquid cooled 4-stroke, DOHC
Forward inclined parallel 2-cylinder
499cc
66 x 73mm
10.1:1
1450kPa/360r/min (14.5kgf/cm2/360r/min)
Electric starter
Dry sump
SAE 10W30SE or SAE10W40SE
SAE80API ”GL-4” hypoid gear oil
2.8L
2.9L
3.6L
0.7L
2.4L
Dry element
Regular unleaded gasoline
14L
BS30/2
Mikuni
CR7E
NGK
0.7~0.8mm
34
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Clutch type
Transmission type
Chassis:
Frame type
Caster angle
Trail
Tire:
Tire type
Size(front)
Size(rear)
Manufacturer (front)
Manufacturer (rear)
Brake:
Front brake type
Rear brake type
Suspension:
Front suspension
Rear suspension
Shock Absorber:
Front fork type
Rear shock absorber assembly type
Wheel Travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system type
Charging system type
Battery voltage/capacity
Battery type
Headlight type
Headlight bulb type
Bulbs (voltage/wattage x quantity)
Headlight
Headlight
Auxiliary light
Brake /tail light
Front flasher light
Rear flasher light
Licence plate light
Meter light
Indicator light
Turn indicator light
Helical gear/spur gear
52/32x36/22(2.659)
Chain drive
41/25x40/29(2.262)
Wet multiple-disc automation
V-Belt automatic
Diamond
28º
95mm
Tubeless
120/70-14M/C 55S
150/70-14M/C 66S
Dunlop/Bridgestone
Dunlop/Bridgestone
Single disc brake
Single disc brake
Telescopic fork
Swingarm
Coil spring/oil damper
Coil spring/gas-oil damper
120mm
120mm
Transistorized coil ignition (digital)
A.C. magneto
12V8Ah
GT9B-4
Bulb type
halogen bulb
12V60W/55Wx1
12V55Wx1
12V5Wx1
12V21W/5Wx2
12V21W/5Wx2
12V21Wx2
12V5Wx1
12V1.7Wx1
12V3.4Wx2
35
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Oil level indicator light
High beam indicator light
V-belt replacement indicator light
Tire pressure (cold):
Loading condition A
Front
Rear
Loading Condition B
Front
Rear
High speed riding
Front
Rear
Maintenance Specification
Cylinder Head
Volume
Max. warpage
Cylinder
Bore
Taper limit
Max. out of round
Chamshaft
Drive system
Camshaft cap inside diameter
Camshaft-journal-to-camshaft-cap clearance
Camshaft lobe dimensions
Intake-measurement A
Intake-measurement B
Intake-measurement C
Exhuast-measurement A
Exhaust-measurement B
Exhaust-measurement C
Valve Timing:
Intake-open (BTDC)((degree))
Intake-closed (ABDC) ((degree))
Exhaust-open (BBDC) ((degree))
Exhaust-closed (ATDC) ((degree))
Overlap angle “A” ((degree))
Max. camshaft runout
Timing Chain:
Model/Number of links
Tensioning system
Valve, valve seat, valve guide:
Valve clearance-intake (cold)
Valve clearance-exhuast (cold)
Valve Dimensions:
Valve head diameter A intake
12V1.7Wx1
12V1.7Wx1
12V1.7Wx1
0~90kg
200kPA(2kgf/cm2)
225kPa(2.25kgf/cm2)
90~183kg
225kPa(2.25kgf/cm2)
250kPa(2.5gf/cm2)
225kPa(2.25kgf/cm2)
250kPa(2.5kgf/cm2)
14.97~15.57cc
0.03mm
66.00~66.01mm
0.05mm
0.05mm
Chain drive(left)
23.000~23.021mm
0.020~0.054mm
33.252~33.352
24.956~25.056
8.196~8.396mm
33.252~33.352
24.956~25.056
8.196~8.396
25º
55º
55º
25º
50º
0.03mm
SCR-0409 SDH/132
Automatic
0.15~0.20mm
0.25~0.30mm
24.9~25.1mm
36
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Valve head diameter A exhaust
Valve face width B intake
Valve face width B exhaust
Valve seat width C intake
Valve seat width C exhaust
Valve margin thickness D intake
Valve margin thickness D exhaust
Valve stem diameter-intake
Valve stem diameter-exhaust
Valve guide inside diameter-intake
Valve guide inside diameter-exhaust
Valve stem to valve guideclearance-intake
Valve stem to valve guideclearance-exhaust
Valve stem runout
Valve seat width-intake
Valve seat width-exhaust
Valve seat material-intake
Valve seat material-exhaust
Valve spring:
Free length-intake
Free length-exhaust
Spring rate-intake (K1)
Spring rate-intake (K2)
Spring rate-exhaust (K1)
Spring rate-exhaust (K2)
Installed length-intake (valve closed)
Installed length-exhaust (valve closed)
Spring tilt-intake ((degree))
Spring tilt-exhaust ((degree))
Winding direction-intake(top view)
Winding direction-exhaust(top view)
Piston:
Piston part number (***-11631-**)
Piston-to-cylinder clearance
<Limit>
Diameter D
Height H
Offset
Offset direction
Piston pin bore inside diameter
Piston pin outside diameter
Piston ring:
Top ring:
Ring type
Dimensions (B x T)
End gap (installed)
Ring side clearance
21.9~22.1mm
1.14~1.98mm
1.14~1.98mm
0.9~1.1mm
0.9~1.1mm
0.6~0.8mm
0.6~0.8mm
3.975~3.990mm
3.960~3.975mm
4.000~4.012mm
4.000~4.012mm
0.010~0.037mm
0.025~0.052mm
0.04mm
0.9~1.1mm
0.9~1.1mm
PB6
V557W
35.59mm
35.59mm
18.845N/mm(1.92kgf/mm)
24.52N/mm(2.5kgf/mm)
18.845N/mm(1.92kgf/mm)
24.52N/mm(2.5kgf/mm)
30.39mm
30.39mm
2.5º/1.6mm
2.5º/1.8mm
Clockwise
Clockwise
5GJ-11631-00
0.020~0.045mm
0.15mm
65.965~65.980mm
9mm
0.5mm
Intake side
16.002~16.013mm
15.991~16.000mm
Barrel
0.80x2.45mm
0.15~0.25mm
0.030~0.065mm
37
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Plating/coating
2nd ring:
Ring type
Dimensions (B x T)
End gap (installed)
Ring side clearance
Plating/coating
Oil ring:
Dimensions (B x T)
End gap (installed)
Ring side clearance
Plating/coating
Connecting rod:
Oil clearance (using plasti-gauge)
Bearing color code
Connecting rod length
Crankshaft:
Width A
Width B
Max. runout C
Big end side clearance D
Big end radial clearance E
Journal oil clearance (using plasti-gauge)
Bearing color code
Ballancer drive method
Clutch:
Friction plate thickness
Plate quantity
Wear limit
Friction plate thickness
Plate quantity
Wear limit
Clutch plate thickness
Plate quantity
Max. warpage
Clutch spring free length
Spring quantity
Minimum length
Clutch spring height
Spring quantity
Minimum height
Clutch spring height
Spring quantity
Minimum height
Clutch release method
Carburetor:
ID mark
Chrome plated/ferox coating
Plain
0.8x2.5mm
0.4~0.5mm
0.020~0.055mm
Parkerrizing
1.5x2.0mm
0.10~0.35mm
0.04~0.16mm
Chrome plated/parkerrizing
0.026~0.050mm
1.Blue 2.Black 3.Brown 4.Green
124.45~124.55mm
50.0~50.6mm
118.55~118.60mm
0.03mm
0.160~0.262mm
0.026~0.050mm
0.040~0.082mm
1.Blue 2.Black 3.Brown 4.Green
Piston
2.75~3.05mm
5pcs
2.65mm
1.8~2.0mm
2pcs
1.7mm
1.3~1.5mm
4pcs
0.1mm
25.9mm
6pcs
25.4mm
4.7mm
1pcs
4.4mm
3.3mm
6pcs
2.9mm
Automatic
5GJ1 00
38
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Fuel level (using special tool)
Main jet
Main air jet
Jet needle
Needle jet
Pilot air jet 1
Pilot air jet 2
Pilot outlet
Pilot jet
Bypass 1
Bypass 2
Bypass 3
Pilot screw turns out
Valve seat size
Throttle valve size
Idling condition:
Engine idle speed
CO% with AIS blocked
Intake vacuum
Water temparature ((degreeC))
Oil temparature ((degree C))
Fuel pump:
Pump type
Model/manufacturer
Consumption amperage (max.)
Output pressure
Oil filter type:
Oil pump:
Oil pump type
Inner rotor to outer rotor tip clearance
Outer rotor to pump housing clearance
Housing and rotor clearance
Bypass valve opening pressure
Relief valve operating pressure
Oil pressure (hot)
Pressure check location
Cooling system:
Radiator core:
Width
Height
Depth
Radiator cap opening pressure
Coolant reservoir capacity
<from low to full level>
Water pump:
Water pump type
Reduction ratio
29.5~30.5mm
#102.5
#100
4DK4-3/5
O-0M (#893)
#85
#170
0.8
#22.5
0.8
0.8
0.8
2
1
#117.5
1150~1200r/min
3%
35kPa(263mmHg)
85~100ºc
70ºc
Electrical
3LN/MITSUBISHI
0.8A
8.3~12.3kPa(0.08~0.12kgf/cm2)
Wire mesh
Trochoid
0.04~0.12mm
0.045~0.085mm
0.11~0.23mm
80~120kPa(0.8~1.2kgf/cm2)
450~550kPa(4.5~5.5kgf/cm2)
150kPa/1200r/min(1.5kgf/cm2/1200r/min)
MAIN GALLERY
330mm
138mm
24mm
107.9~137.3kPa(1.08~1.37kgf/cm2)
0.6L
0.25L
Single suction centrifugal pump
23/19(1.210)
39
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Steering:
Steering bearing type
Lock to lock angle (left)((degree))
Lock to lock angle (Right)((degree))
Front suspension:
Front fork travel
Fork spring free length
Installed length
Collar length
Spring rate (K 1)
Spring rate (K 2)
Spring rate (K 3)
Spring stroke (K 1)
Spring stroke (K 2)
Spring stroke (K 3)
Optional spring available
Oil Quantity
Oil Level
Recommended oil
Inner tube outer diameter
Rear suspension:
Rear shock absorber assembly travel
Spring free length
Installed length
Spring rate (K 1)
Spring rate (K 2)
Spring stroke (K 1)
Spring stroke (K 2)
Optional spring available
Enclosed gas/air pressure(STD)
Swingarm:
Free play limit(at the end of the swingarm)-radial
Free play limit(at the end of the swingarm)-axial
Front wheel:
Wheel type
Rim size
Rim material
Max. radial wheel runout
Max. lateral wheel runout
Rear wheel:
Wheel type
Rim size
Rim material
Max. radial wheel runout
Max. lateral wheel runout
Front disc brake:
Disc brake type
Angular bearing
38.5º
38.5º
120mm
428.5mm
419.5mm
129.6mm
11.8N/mm(1.2kgf/mm)
15.7N/mm(1.6kgf/mm)
19.6N/mm(2kgf/mm)
0~19mm
19~83mm
83~120mm
No
402cc
135mm
Fork oil 7.5W or equivalent
38mm
44.5mm
190mm
180mm
226N/mm(23.05kgf/mm)
294N/mm(29.98kgf/mm)
0~30mm
30.0~44.5mm
No
4900kPa(49kgf/cm2)
1mm
1mm
Cast wheel
14M/C x MT3.50
Aluminum
1mm
0.5mm
Cast wheel
14M/C x MT4.50
Aluminum
1mm
0.5mm
Single
40
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Disc outside diameter x thickness
Max. deflection
Brake pad lining thickness-inner
<Limit>
Brake pad lining thickness-outer
<Limit>
Master cylinder inside diameter
Caliper cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Rear disc brake:
Disc brake type
Disc outside diameter x thickness
Max. deflection
Brake pad lining thickness-inner
<Limit>
Brake pad lining thickness-outer
<Limit>
Master cylinder inside diameter
Caliper cylinder inside diameter
Recommended fluid
Brake lever and brake pedal:
Brake lever free play (pivot)
Brake lever free play (lever end)
Throttle grip free play
Ignition system:
Ignition timing (B.T.D.C.)((degree))
Advancer type
Transistorized coil ignition:
Pickup coil resistance ((ohm))
T.C.I. unit model/manufacturer
Ignition coil:
Model/manufacturer
Primary coil resistance ((ohm))
Secondary coil resistance((k ohm))
Spark plug cap:
Material
Resistance ((k ohm))
A.C. magneto:
Model/manufacturer
Standard output
Stator coil resistance ((ohm))
Rectifier/regulator:
Regulator type
Model/manufacturer
No load regulated voltage(DC)
Rectifier capacity (DC)
282x5mm
0.15mm
6mm
0.8mm
6mm
0.8mm
14mm
30.16mm
33.34mm
Dot 4
Single
267x5mm
0.15mm
8.3mm
0.8mm
8.3mm
0.8mm
12.7mm
38.1mm
Dot 4
1.8~2.6mm
6.7~14.1mm
3~5mm
10º/1200r/min
Digital
210Ω+-10%Gy-B
J4T120/MITSUBISHI
JO313/DENSO
2.2Ω+-15%
15KΩ+-20%
Resin
10KΩ
F4T373/MITSUBISHI
14V310W5000r/min
0.375Ω+-10%W-W
Semi conductor-short circuit
SH650A-12/SHINDENGEN
14.5<+->0.4V
18A
41
XP500 TMax Technical Orientation Guide
GENERAL SPECIFICATIONS
Withstand voltage
Battery:
Specific gravity
Electric starting system:
System type
Starter motor:
Model/manufacturer
Power output
Armature coil resistance ((ohm))
Brush overall length
<Limit>
Brush spring force
Commutator diameter
<Limit>
Mica undercut (depth)
Starter relay:
Model/manufacturer
Amperage
Coil resistance ((ohm))
Horn:
Quantity
Model/manufacturer
Max. amperage
Turn signal/hazard relay:
Relay type
Model/manufacturer
Self cancelling device built-in
Turn signal blinking frequency
Wattage
Fuel gauge:
Model/manufacturer
Sender unit resistance-full ((ohm))
Sender unit resistance-empty ((ohm))
Circuit breaker:
Circuit breaker type
Amperage for fuses:
Main fuse
Headlight fuse
Signaling system fuse
Ignition fuse
Radiator fan fuse
Back up fuse
Reserve fuse
Reserve fuse
Reserve fuse
Thermo-unit:
Model/manufacturer
200V
1.32
Constant mesh
SM-13/YAMAHA
07kW
0.0015~0.0025Ω
12mm
4mm
7.65~10.01N(780~1021gf)
28mm
27mm
0.7mm
MS5F-561/JIDECO
180A
4.4Ω+-5%
Horn type Plane
2pcs
YF-12/NIKKO
3A
Full transistor
FE246BH/DENSO
No
75~95cyl/min
21Wx2+3.4W
5GJ/NIPPON SEIKI
4~10Ω
90~100Ω
Fuse
30A
15A
15A
10A
15A
10A
30A
15A
10A
46X/NIPPON SEIKI
42
XP500 TMax Technical Orientation Guide
WIRING DIAGRAM
44
XP500 TMax Technical Orientation Guide
WIRING DIAGRAM
45